Air cleaner, components thereof, and methods

ABSTRACT

A filter cartridge includes a media pack having first and second opposite flow faces; the media pack comprising flutes extending in a direction between the inlet flow face and the outlet flow face; a frame mounted on the second flow face of the media pack; a seal support section extending from the base member; and first and second opposite and spaced blades extending from the base member and in a different direction from the base member as the seal support section. The first and second blades are embedded within the media pack through the second flow face. A seal member is oriented against the seal support section. The filter cartridge can be removably oriented in a cassette. The cassette and filter cartridge are removably oriented in an air cleaner housing. The cassette may include lugs to help position the cartridge in sealing engagement with the air cleaner housing. In another embodiment, the filter cartridge is cassette-free and includes a cartridge-handle projecting therefrom.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/584,150, filed Dec. 29, 2014 which is a continuation of U.S. patentapplication Ser. No. 13/262,037, filed Jan. 13, 2012 issued as U.S. Pat.No. 8,920,528 on Dec. 30, 2014, which is a 371 U.S. National Stage ofPCT International Patent application No. PCT/US2010/029426, filed 31Mar. 2010, and claims priority to U.S. Provisional patent applicationSer. No. 61/165,276, filed Mar. 31, 2009, and 61/296,711, filed Jan. 20,2010, which applications are incorporated herein by reference. To theextent appropriate, a claim of priority is made to each of the abovedisclosed applications.

TECHNICAL FIELD

The present disclosure relates to filter constructions for filteringfluids, such as liquids or gases. This particular disclosure concerns:straight through flow filter cartridges; safety filters; assembliesemploying such filters; precleaners; and methods for use of, andassembly of, filter cartridges.

BACKGROUND

Straight through flow filters (filter elements or filter cartridges)have been used in various systems for filtering fluids such as gases orliquids. Straight through flow filters typically have an inlet face (orend) and an oppositely disposed outlet face (or end). During filtering,the fluid to be filtered flows in one direction upon entering the filterat the inlet face, and has the same general direction of flow as itexists the outlet face. Typically, a straight through flow filter isinstalled in housing, for use. After a period of use, the filterrequires servicing, either through cleaning or complete replacement ofthe filter. A seal is necessary between the filter and a portion of thehousing in which the filter is placed in use, to ensure proper filteringof the fluid flow through the arrangement.

Improvements in straight through flow filters, their assembly and theiruse are desirable.

SUMMARY

According to the present disclosure, a filter element or cartridge isprovided. The filter element or cartridge in general has a straightthrough flow construction and comprises z-filter media. The filterelement or cartridge includes a seal gasket.

A particular type of air filter cartridge is of concern to the presentdisclosure. In general, the air filter cartridge comprises: A media packhaving first and second opposite flow faces; the media pack comprising aplurality of flutes extending in a direction between the inlet flow faceand the outlet flow face; the media pack being closed to air enteringthe inlet flow face and passing outwardly from the outward flow facewithout filtering through media of the media pack; a frame mounted onthe second flow face of the media pack; the frame includes a base memberdefining an air flow opening arrangement in communication with thesecond flow face; a seal support section extending from the base memberalong a perimeter of the air flow opening arrangement; first and secondopposite and spaced blades extending from the base member and in adifferent direction from the base member as the seal support section;the first and second blades are embedded within the media pack throughthe second flow face; and a seal member is oriented against the sealsupport section.

Preferably, in one embodiment, the media pack comprises a stack ofstrips of single facer filter media material, each strip including afluted media sheet secured to a facing media sheet and oriented withflutes of each fluted sheet extending in a direction between the firstand second opposite flow faces. In one arrangement, the first bladeextends from the base member into the media pack between adjacent stripsof single facer media. The second blade extends from the base memberinto the media pack between adjacent strips of single facer media.

In one arrangement, the media pack has first and second opposite sidesextending between the first and second opposite flow faces. Thecartridge can further include a first side panel secured to the firstside of the media pack and a second side panel secured to the secondside of the media pack.

Preferably, the first and second blades are connected only by anintervening portion of the base.

In another aspect, a filter cartridge and cassette assembly is provided.In general, the assembly includes a filter cartridge and a cassette. Atleast a portion of the filter cartridge is removably oriented in theinterior volume of the cassette. The filter cartridge includes a mediapack of z-filter media, and a seal member secured to the media pack. Oneexample cassette includes a surrounding wall defining an open interiorvolume, a plurality of lugs extending from the exterior surfaces of thefirst and second side walls. The first flow face of the filter cartridgeopposes the at least one cross-piece of the first open end of thecassette. In one example, the seal member is outside of the cassette andadjacent to the second open end of the cassette.

In one example, there is at least one cross-piece extending over a firstopen end and in engagement with the surrounding wall

In another aspect, an air cleaner is provided. The air cleaner includesa housing including a surrounding housing-wall defining an openinterior, an inlet arrangement, and an outlet arrangement which are atopposite ends of the housing; the housing defining an access opening incommunication with the open interior; the surrounding housing-walldefining a plurality of opposing receiving grooves, each of the groovesbeing in open communication with the access opening and being locatedcloser to the outlet arrangement than to the inlet arrangement.

A cover is removably secured to the housing over the access opening. Afilter cartridge and cassette assembly is operably oriented forselective removal within the open interior between the inlet arrangementand the outlet arrangement. The filter cartridge includes a media packhaving first and second opposite flow faces and comprising a pluralityof flutes extending in a direction between the inlet flow face and theoutlet flow face, the media pack being closed to air entering the inletflow face and passing outwardly from the outlet flow face withoutfiltering flow through media of the media pack, and a seal membersecured to the media pack which forms a releasable seal with a sealingsurface in the housing.

The cassette includes a surrounding cassette-wall defining an openinterior volume therewithin. The cassette-wall has first and secondopposite open ends in communication with the interior volume. Thecassette-wall has first and second opposite side walls defining aninterior surface in communication with the interior volume and anopposite exterior surface. The second open end is an opening sized topermit the filter cartridge to be operably inserted and removed from theinterior volume of the cassette. A plurality of lugs extend from theexterior surfaces of the first and second side walls. Each lug of theplurality of lugs is positioned within a respective one of the receivinggrooves. At least a portion of the filter cartridge is removablyoriented in the interior volume of the cassette. The first flow face islocated adjacent to the first opening end of the cassette, and the sealmember is outside of the cassette and adjacent to the second open end ofthe cassette.

In one example embodiment, the cover further includes a grip projectingfrom a remaining portion of the cover and extending over a portion ofthe inlet arrangement. In one example, the cassette further includes acassette-handle sized to accommodate at least a portion of a human hand.The cassette-handle projects from the cassette-wall.

Preferably, the cover has an exterior surface and an opposite interiorsurface, in which the interior surface includes a receiver that containsat least a portion of the cassette-handle when the filter cartridge andcassette assembly are operably oriented within the housing interior andwhen the cover is secured over the access opening.

In one example embodiment, a safety element is removably sealed betweenthe filter cartridge and the outlet arrangement.

In one example embodiment, the inlet arrangement includes a precleaner,which comprises a plurality of centrifugal separator tubes.

In another aspect, a method of installing a filter cartridge into an aircleaner is provided. The method includes providing a filter cartridgeincluding a media pack having first and second opposite flow faces. Themedia pack comprises a plurality of flutes extending in a directionbetween the inlet flow face and the outlet flow face. The media pack isclosed to air entering the inlet flow face and passing outwardly fromthe outlet flow face without filtering flow through media of the mediapack. A seal member is secured to the media pack.

There is a step of providing a cassette having a surroundingcassette-wall, with lugs projecting from an exterior portion of thecassette-wall, and a handle extending from the cassette-wall. Next, thefilter cartridge is oriented partially into an interior of the cassetteso that the seal member is outside of the cassette to provide a filtercartridge and cassette assembly. The filter cartridge and cassetteassembly are oriented into an access opening in an air cleaner housing.The access opening is between an air cleaner inlet arrangement and anair cleaner outlet arrangement.

While orienting the filter cartridge and cassette assembly in the accessopening, there is a step of orienting the lugs into a grooves in thehousing adjacent to the air cleaner outlet arrangement. Next, the handleis grasped to move the filter cartridge and cassette assembly so thatthe seal member is urged against a sealing surface in the housing toform a releasable seal.

Herein, a variety of features, arrangements and techniques are providedthat can be incorporated into air cleaner arrangements, to advantage.Selected ones of the techniques features arrangements can be utilized,to advantage. Together, some particularly preferred arrangements areprovided. However, it is not a requirement that all filter elements orassemblies must incorporate all advantageous features herein to obtainbenefit and advantage according to the present disclosure. Theindividual features, techniques, and advantages can be selected and beselectively combined for various alternate arrangements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary, schematic, perspective view of a single facerstrip of z-filter media comprising a fluted sheet secured into a facingsheet.

FIG. 2 is an enlarged, schematic, fragmentary view of a single facersheet comprising fluted media secured to facing media.

FIG. 3 is a schematic view of various selected flute shapes.

FIG. 3A includes a schematic, fragmentary, cross-sectional view of afurther fluted media configuration in a single facer media pack.

FIG. 3B includes a schematic, fragmentary, cross-sectional view of astill further alternate flute definition and media pack comprisingsingle facer strips.

FIG. 3C includes a schematic, fragmentary, cross-sectional view of yetanother flute definition in a media pack comprising single facer strips.

FIG. 4 is a schematic view of a process for making single facer mediaaccording to the present disclosure.

FIG. 5 is schematic, cross-sectional view of an example darted flute.

FIG. 6 is schematic, perspective view of a coiled media constructioncomprising a coiled sheet of single facer material.

FIG. 7 is a schematic, perspective view of a stacked media construction.

FIG. 8 is a perspective view of a first embodiment of an air cleanerconstructed in accordance with principles of this disclosure.

FIG. 9 is an exploded perspective view of the air cleaner of FIG. 8showing the internal components including a filter cartridge andcassette assembly and a safety element.

FIG. 10 is a side elevational view of the air cleaner of FIG. 8.

FIG. 11 is an exploded perspective view of an air filter cartridgeutilized in the air cleaner of FIGS. 8-10.

FIG. 12 is a perspective view of the assembled air filter cartridge ofFIG. 11.

FIG. 13 is an end view of the air filter cartridge of FIG. 12.

FIG. 14 is a cross-sectional view of the filter cartridge of FIGS. 12and 13, the cross-section being taken along the line 14-14 of FIG. 13.

FIG. 15 is a cross-sectional view of the filter cartridge of FIGS. 12and 13, the cross-section being taken along the line 15-15 of FIG. 13.

FIG. 16 is a side elevational view of the seal member used with thefilter cartridge of FIGS. 12-14.

FIG. 16A is an enlarged view of a portion of the seal member of FIG. 16.

FIG. 17 is a perspective view of a frame that is part of the air filtercartridge of FIGS. 12-15.

FIG. 18 is a top plan view of the frame of FIG. 17.

FIG. 19 is a cross-sectional view of the frame of FIG. 18, thecross-section being taken along the line 19-19 of FIG. 18.

FIG. 20 is a cross-sectional view of the frame of FIG. 18, thecross-section being taken along the line 20-20 of FIG. 18.

FIG. 21 is a perspective view of the filter cartridge and cassetteassembly which is utilized in the air cleaner assembly of FIGS. 8-10.

FIG. 22 is an end elevational view of the filter cartridge and cassetteassembly of FIG. 21.

FIG. 23 is a cross-sectional view of the filter cartridge and cassetteassembly of FIG. 22, the cross-section being taken along the line 23-23of FIG. 22.

FIG. 24 is a side elevational view of the filter cartridge and cassetteassembly of FIG. 22, with a portion of the cassette broken away to showan internal cross-section.

FIG. 25 is a perspective view of the cassette utilized in the filtercartridge and cassette assembly of FIGS. 21-24.

FIG. 26 is another perspective view of the cassette of FIG. 25.

FIG. 27 is a front elevational view of the cassette of FIG. 25.

FIG. 28 is a cross-sectional view of the cassette of FIG. 27, thecross-section being taken along the line 28-28 of FIG. 27.

FIG. 29 is a perspective view of a safety filter element utilized in theair cleaner of FIGS. 8-10.

FIG. 30 is an end elevational view of the air cleaner of FIG. 8.

FIG. 31 is a cross-sectional view of the air cleaner of FIG. 30, thecross-section being taken along the line 31-31 of FIG. 30.

FIG. 32 is a cross-sectional view of the air cleaner of FIG. 30, thecross-section being taken along the line 32-32 of FIG. 30.

FIG. 33 is a top plan view of the access cover for the air cleaner ofFIGS. 8-12.

FIG. 34 is a cross-sectional view of the access cover of FIG. 33, thecross-section being taken along the line 34-34 of FIG. 33.

FIG. 35 is a perspective view of another embodiment of a filtercartridge and cassette assembly usable with the air cleaner of FIG. 8.

FIG. 36 is a top view of the cassette of FIG. 35.

FIG. 37 is a perspective view of another embodiment of an air cleaner,constructed in accordance with principles of this disclosure.

FIG. 38 is an exploded perspective view of the air cleaner of FIG. 37showing the internal components including a filter cartridge and asafety element.

FIG. 39 is a top view of the access cover for the air cleaner of FIG.37.

FIG. 40 is a cross-sectional view of the access cover of FIG. 39, thecross-section being taken along the line 40-40 of FIG. 39.

FIG. 41 is a cross-sectional view of the filter cartridge used in theair cleaner of FIG. 37, the cross-section being taken along the line41-41 of FIG. 42.

FIG. 42 is a side elevational view of the filter cartridge used in theair cleaner of FIG. 37.

FIG. 43 is a perspective view of a shell that is part of the filtercartridge of FIGS. 41 and 42.

FIG. 44 is a top view of the shell of FIG. 43.

FIG. 45 is a cross-sectional view of the shell of FIGS. 43 and 44, thecross-section being taken along the line 45-45 of FIG. 44.

FIG. 46 is a schematic cross-sectional view of the air cleaner of FIG.37 showing the internal components.

FIG. 47 is an end view of the filter cartridge depicted in theembodiment of FIG. 35.

FIG. 48 is a side elevational view of the filter cartridge depicted inFIGS. 35 and 47.

DETAILED DESCRIPTION

I. Z-Filter Media Configurations, Generally.

Fluted filter media can be used to provide fluid filter constructions ina variety of manners. One well known manner is as a z-filterconstruction. The term “z-filter construction” as used herein, is meantto refer to a filter construction in which individual ones ofcorrugated, folded or otherwise formed filter flutes are used to definesets of longitudinal filter flutes for fluid flow through the media; thefluid flowing along the length of the flutes between opposite inlet andoutlet flow ends (or flow faces) of the media. Some examples of z-filtermedia are provided in U.S. Pat. Nos. 5,820,646; 5,772,883; 5,902,364;5,792,247; 5,895,574; 6,210,469; 6,190,432; 6,350,296; 6,179,890;6,235,195; Des. 399,944; Des. 428,128; Des. 396,098; Des. 398,046; and,Des. 437,401; each of these fifteen cited references being incorporatedherein by reference.

One type of z-filter media utilizes two specific media components joinedtogether, to form the media construction. The two components are: (1) afluted (typically corrugated) media sheet; and, (2) a facing mediasheet. The facing media sheet is typically non-corrugated, however itcan be corrugated, for example perpendicularly to the flute direction asdescribed in U.S. provisional 60/543,804, filed Feb. 11, 2004,incorporated herein by reference.

The fluted (typically corrugated) media sheet and the facing mediasheet, together, are used to define media having parallel inlet andoutlet flutes; i.e. opposite sides of the fluted sheet operable as inletand outlet flow regions. In some instances, the fluted sheet andnon-fluted sheet are secured together and are then coiled to form az-filter media construction. Such arrangements are described, forexample, in U.S. Pat. Nos. 6,235,195 and 6,179,890, each of which isincorporated herein by reference. In certain other arrangements, somenon-coiled sections of fluted media secured to flat media, are stackedon one another, to create a filter construction. An example of this isshown herein at FIG. 7 and described in FIG. 11 of U.S. Pat. No.5,820,646, incorporated herein by reference.

Typically, coiling of the fluted sheet/facing sheet combination arounditself, to create a coiled media pack, is conducted with the facingsheet directed outwardly. Some techniques for coiling are described inU.S. provisional application 60/467,521, filed May 2, 2003 and PCTApplication US 04/07927, filed Mar. 17, 2004, published Sep. 30, 2004 asWO 2004/082795, incorporated herein by reference. The resulting coiledarrangement generally has, as the outer surface of the media pack, aportion of the facing sheet, as a result. In some instances a protectivecovering can be provided around the media pack.

The term “corrugated” when used herein to refer to structure in media,is meant to refer to a flute structure resulting from passing the mediabetween two corrugation rollers, i.e., into a nip or bite between tworollers, each of which has surface features appropriate to cause acorrugation affect in the resulting media. The term “corrugation” is notmeant to refer to flutes that are formed by techniques not involvingpassage of media into a bite between corrugation rollers. However, theterm “corrugated” is meant to apply even if the media is furthermodified or deformed after corrugation, for example by the foldingtechniques described in PCT WO 04/007054, published Jan. 22, 2004,incorporated herein by reference.

Corrugated media is a specific form of fluted media. Fluted media ismedia which has individual flutes (for example formed by corrugating orfolding) extending there across.

Serviceable filter element or filter cartridge configurations utilizingz-filter media are sometimes referred to as “straight through flowconfigurations” or by variants thereof. In general, in this context whatis meant is that the serviceable filter elements generally have an inletflow end (or face) and an opposite exit flow end (or face), with flowentering and exiting the filter cartridge in generally the same straightthrough direction. (The term “straight through flow configuration”disregards, for this definition, any air flow that passes out of themedia pack through the outermost wrap of facing media.) The term“serviceable” in this context is meant to refer to a media containingfilter cartridge that is periodically removed and replaced from acorresponding air cleaner. In some instances, each of the inlet flow endand outlet flow end will be generally flat or planar, with the twoparallel to one another. However, variations from this, for examplenon-planar faces are possible.

In general, the media pack includes appropriate seal material therein,to ensure there is no unfiltered flow of air through the media pack, inextension from front flow face (an inlet flow face) completely throughand outwardly from opposite oval face (outlet flow face).

A straight through flow configuration (especially for a coiled mediapack) is, for example, in contrast to serviceable filter cartridges suchas cylindrical pleated filter cartridges of the type shown in U.S. Pat.No. 6,039,778, incorporated herein by reference, in which the flowgenerally makes a turn as its passes through the serviceable cartridge.That is, in a U.S. Pat. No. 6,039,778 filter, the flow enters thecylindrical filter cartridge through a cylindrical side, and then turnsto exit through an end face (in forward-flow systems). In a typicalreverse-flow system, the flow enters the serviceable cylindricalcartridge through an end face and then turns to exit through a side ofthe cylindrical filter cartridge. An example of such a reverse-flowsystem is shown in U.S. Pat. No. 5,613,992, incorporated by referenceherein.

The term “z-filter media construction” and variants thereof as usedherein, without more, is meant to refer to any or all of: a web ofcorrugated or otherwise fluted media secured to (facing) media withappropriate sealing to inhibit air flow from one flow face to anotherwithout filtering passage through the filter media; and/or, such a mediacoiled or otherwise constructed or formed into a three dimensionalnetwork of flutes; and/or, a filter construction including such media.In many arrangements, the z-filter media construction is configured forthe formation of a network of inlet and outlet flutes, inlet flutesbeing open at a region adjacent an inlet face and being closed at aregion adjacent an outlet face; and, outlet flutes being closed adjacentan inlet face and being open adjacent an outlet face. However,alternative z-filter media arrangements are possible, see for example US2006/0091084 A1, published May 4, 2006, incorporated herein byreference; also comprising flutes extending between opposite flow faces,with a seal arrangement to prevent flow of unfiltered air through themedia pack.

In FIG. 1 herein, an example of media 1 useable in z-filter media isshown. The media 1 is formed from a fluted (corrugated) sheet 3 and afacing sheet 4. Herein, a strip of media comprising fluted sheet securedto facing sheet will sometimes be referred to as a single facer strip,or by similar terms.

In general, the corrugated sheet 3, FIG. 1 is of a type generallycharacterized herein as having a regular, curved, wave pattern of flutesor corrugations 7. The term “wave pattern” in this context, is meant torefer to a flute or corrugated pattern of alternating troughs 7 b andridges 7 a. The term “regular” in this context is meant to refer to thefact that the pairs of troughs and ridges (7 b, 7 a) alternate withgenerally the same repeating corrugation (or flute) shape and size.(Also, typically in a regular configuration each trough 7 b issubstantially an inverse of each ridge 7 a.) The term “regular” is thusmeant to indicate that the corrugation (or flute) pattern comprisestroughs and ridges with each pair (comprising an adjacent trough andridge) repeating, without substantial modification in size and shape ofthe corrugations along at least 70% of the length of the flutes. Theterm “substantial” in this context, refers to a modification resultingfrom a change in the process or form used to create the corrugated orfluted sheet, as opposed to minor variations from the fact that themedia sheet 3 is flexible. With respect to the characterization of arepeating pattern, it is not meant that in any given filterconstruction; an equal number of ridges and troughs are necessarilypresent. The media 1 could be terminated, for example, between a paircomprising a ridge and a trough, or partially along a pair comprising aridge and a trough. (For example, in FIG. 1 the media 1 depicted infragmentary has eight complete ridges 7 a and seven complete troughs 7b.) Also, the opposite flute ends (ends of the troughs and ridges) mayvary from one another. Such variations in ends are disregarded in thesedefinitions, unless specifically stated. That is, variations in the endsof flutes are intended to be covered by the above definitions.

In the context of the characterization of a “curved” wave pattern ofcorrugations, the term “curved” is meant to refer to a corrugationpattern that is not the result of a folded or creased shape provided tothe media, but rather the apex 7 a of each ridge and the bottom 7 b ofeach trough is formed along a radiused curve. Although alternatives arepossible, a typical radius for such z-filter media would be at least0.25 mm and typically would be not more than 3 mm. (Media that is notcurved, by the above definition, can also be useable.)

An additional characteristic of the particular regular, curved, wavepattern depicted in FIG. 1, for the corrugated sheet 3, is that atapproximately a midpoint 30 between each trough and each adjacent ridge,along most of the length of the flutes 7, is located a transition regionwhere the curvature inverts. For example, viewing back side or face 3 a,FIG. 1, trough 7 b is a concave region, and ridge 7 a is a convexregion. Of course when viewed toward front side or face 3 b, trough 7 bof side 3 a forms a ridge; and, ridge 7 a of face 3 a, forms a trough.(In some instances, region 30 can be a straight segment, instead of apoint, with curvature inverting at ends of the segment 30.)

A characteristic of the particular regular, curved, wave patterncorrugated sheet 3 shown in FIG. 1, is that the individual corrugationsare generally straight. By “straight” in this context, it is meant thatthrough at least 70% (typically at least 80%) of the length betweenedges 8 and 9, the ridges 7 a and troughs 7 b do not changesubstantially in cross-section. The term “straight” in reference tocorrugation pattern shown in FIG. 1, in part distinguishes the patternfrom the tapered flutes of corrugated media described in FIG. 1 of WO97/40918 and PCT Publication WO 03/47722, published Jun. 12, 2003,incorporated herein by reference. The tapered flutes of FIG. 1 of WO97/40918, for example, would be a curved wave pattern, but not a“regular” pattern, or a pattern of straight flutes, as the terms areused herein.

Referring to the present FIG. 1 and as referenced above, the media 1 hasfirst and second opposite edges 8 and 9. When the media 1 is coiled andformed into a media pack, in general edge 9 will form an inlet end forthe media pack and edge 8 an outlet end, although an oppositeorientation is possible.

In the example shown, adjacent edge 8 is provided sealant, in thisinstance in the form of a sealant bead 10, sealing the corrugated(fluted) sheet 3 and the facing sheet 4 together. Bead 10 will sometimesbe referred to as a “single facer” bead, since it is a bead between thecorrugated sheet 3 and facing sheet 4, which forms the single facer ormedia strip 1. Sealant bead 10 seals closed individual flutes 11adjacent edge 8, to passage of air therefrom.

In the example shown, adjacent edge 9, is provided sealant, in thisinstance in the form of a seal bead 14. Seal bead 14 generally closesflutes 15 to passage of unfiltered fluid therein, adjacent edge 9. Bead14 would typically be applied as the media 1 is coiled about itself,with the corrugated sheet 3 directed to the inside. Thus, bead 14 willform a seal between a back side 17 of facing sheet 4, and side 18 of thecorrugated sheet 3. The bead 14 will sometimes be referred to as a“winding bead” since it is typically applied, as the strip 1 is coiledinto a coiled media pack. If the media 1 is cut in strips and stacked,instead of coiled, bead 14 would be a “stacking bead.”

Referring to FIG. 1, once the media 1 is incorporated into a media pack,for example by coiling or stacking, it can be operated as follows.First, air in the direction of arrows 12, would enter open flutes 11adjacent end 9. Due to the closure at end 8, by bead 10, the air wouldpass through the media shown by arrows 13. It could then exit the mediapack, by passage through open ends 15 a of the flutes 15, adjacent end 8of the media pack. Of course operation could be conducted with air flowin the opposite direction.

In more general terms, z-filter media comprises fluted filter mediasecured to facing filter media, and configured in a media pack of flutesextending between first and second opposite flow faces. A sealantarrangement is provided within the media pack, to ensure that airentering flutes at a first upstream edge cannot exit the media pack froma downstream edge, without filtering passage through the media.

For the particular arrangement shown herein in FIG. 1, the parallelcorrugations 7 a, 7 b are generally straight completely across themedia, from edge 8 to edge 9. Straight flutes or corrugations can bedeformed or folded at selected locations, especially at ends.Modifications at flute ends for closure are generally disregarded in theabove definitions of “regular,” “curved” and “wave pattern.”

Z-filter constructions which do not utilize straight, regular curvedwave pattern corrugation (flute) shapes are known. For example in Yamadaet al. U.S. Pat. No. 5,562,825 corrugation patterns which utilizesomewhat semicircular (in cross section) inlet flutes adjacent narrowV-shaped (with curved sides) exit flutes are shown (see FIGS. 1 and 3,of U.S. Pat. No. 5,562,825). In Matsumoto, et al. U.S. Pat. No.5,049,326 circular (in cross-section) or tubular flutes defined by onesheet having half tubes attached to another sheet having half tubes,with flat regions between the resulting parallel, straight, flutes areshown, see FIG. 2 of Matsumoto '326. In Ishii, et al. U.S. Pat. No.4,925,561 (FIG. 1) flutes folded to have a rectangular cross section areshown, in which the flutes taper along their lengths. In WO 97/40918(FIG. 1), flutes or parallel corrugations which have a curved, wavepatterns (from adjacent curved convex and concave troughs) but whichtaper along their lengths (and thus are not straight) are shown. Also,in WO 97/40918 flutes which have curved wave patterns, but withdifferent sized ridges and troughs, are shown.

In general, the filter media is a relatively flexible material,typically a non-woven fibrous material (of cellulose fibers, syntheticfibers or both) often including a resin therein, sometimes treated withadditional materials. Thus, it can be conformed or configured into thevarious corrugated patterns, without unacceptable media damage. Also, itcan be readily coiled or otherwise configured for use, again withoutunacceptable media damage. Of course, it must be of a nature such thatit will maintain the required corrugated configuration, during use.

In the corrugation process, an inelastic deformation is caused to themedia. This prevents the media from returning to its original shape.However, once the tension is released the flute or corrugations willtend to spring back, recovering only a portion of the stretch andbending that has occurred. The facing sheet is sometimes tacked to thefluted sheet, to inhibit this spring back in the corrugated sheet.

Also, typically, the media contains a resin. During the corrugationprocess, the media can be heated to above the glass transition point ofthe resin. When the resin then cools, it will help to maintain thefluted shapes.

The media of the corrugated sheet 3 facing sheet 4 or both, can beprovided with a fine fiber material on one or both sides thereof, forexample in accord with U.S. Pat. No. 6,673,136, incorporated herein byreference.

An issue with respect to z-filter constructions relates to closing ofthe individual flute ends. Typically a sealant or adhesive is provided,to accomplish the closure. As is apparent from the discussion above, intypical z-filter media especially those which use straight flutes asopposed to tapered flutes, large sealant surface areas (and volume) atboth the upstream end and the downstream end are needed. High qualityseals at these locations are critical to proper operation of the mediastructure that results. The high sealant volume and area, creates issueswith respect to this.

Still referring to FIG. 1, at 20 tack beads are shown positioned betweenthe corrugated sheet 3 and facing sheet 4, securing the two together.The tack beads can be for example, discontinuous lines of adhesive. Thetack beads can also be points in which the media sheets are weldedtogether.

From the above, it will be apparent that the corrugated sheet 3 istypically not secured continuously to the facing sheet, along thetroughs or ridges where the two adjoin. Thus, air can flow betweenadjacent inlet flutes, and alternately between the adjacent outletflutes, without passage through the media. However air which has enteredin inlet flute cannot exit from an outlet flute, without passing throughat least one sheet of media, with filtering.

Attention is now directed to FIG. 2, in which a z-filter mediaconstruction 40 utilizing a fluted (in this instance regular, curved,wave pattern corrugated) sheet 43, and a non-corrugated flat, facing,sheet 44, is depicted. The distance D1, between points 50 and 51,defines the extension of flat media 44 in region 52 underneath a givencorrugated flute 53. The length D2 of the arch-shaped media for thecorrugated flute 53, over the same distance D1 is of course larger thanD1, due to the shape of the corrugated flute 53. For a typical regularshaped media used in fluted filter applications, the linear length D2 ofthe media 53 between points 50 and 51 will generally be at least 1.2times D1. Typically, D2 would be within a range of 1.2-2.0, inclusive.One particularly convenient arrangement for air filters has aconfiguration in which D2 is about 1.25-1.35×D1. Such media has, forexample, been used commercially in Donaldson Powercore™ Z-filterarrangements. Herein the ratio D2/D1 will sometimes be characterized asthe flute/flat ratio or media draw for the corrugated media.

In the corrugated cardboard industry, various standard flutes have beendefined. For example the standard E flute, standard X flute, standard Bflute, standard C flute and standard A flute. FIG. 3, attached, incombination with Table A below provides definitions of these flutes.

Donaldson Company, Inc., (DCI) the assignee of the present disclosure,has used variations of the standard A and standard B flutes, in avariety of z-filter arrangements. These flutes are also defined in TableA and FIG. 3.

TABLE A (Flute definitions for FIG. 3) DCI A Flute: Flute/flat = 1.52:1;The Radii (R) are as follows: R1000 = .0675 inch (1.715 mm); R1001 =.0581 inch (1.476 mm); R1002 = .0575 inch (1.461 mm); R1003 = .0681 inch(1.730 mm); DCI B Flute: Flute/flat = 1.32:1; The Radii (R) are asfollows: R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm);R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm); Std. EFlute: Flute/flat = 1.24:1; The Radii (R) are as follows: R1008 = .0200inch (.508 mm); R1009 = .0300 inch (.762 mm); R1010 = .0100 inch (.254mm); R1011 = .0400 inch (1.016 mm); Std. X Flute: Flute/flat = 1.29:1;The Radii (R) are as follows: R1012 = .0250 inch (.635 mm); R1013 =.0150 inch (.381 mm); Std. B Flute: Flute/flat = 1.29:1; The Radii (R)are as follows: R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874mm); R1016 = .0310 inch (.7874 mm); Std. C Flute: Flute/flat = 1.46:1;The Radii (R) are as follows: R1017 = .0720 inch (1.829 mm); R1018 =.0620 inch (1.575 mm); Std. A Flute: Flute/flat = 1.53:1; The Radii (R)are as follows: R1019 = .0720 inch (1.829 mm); R1020 = .0620 inch (1.575mm).

Of course other, standard, flutes definitions from the corrugated boxindustry are known.

In general, standard flute configurations from the corrugated boxindustry can be used to define corrugation shapes or approximatecorrugation shapes for corrugated media. Comparisons above between theDCI A flute and DCI B flute, and the corrugation industry standard A andstandard B flutes, indicate some convenient variations.

It is noted that alternative flute definitions such as thosecharacterized in U.S. Ser. No. 12/215,718, filed Jun. 26, 2008; and Ser.No. 12/012,785, filed Feb. 4, 2008 can be used, with air cleanerfeatures as characterized herein below. The complete disclosures of eachof U.S. Ser. Nos. 12/215,718 and 12/012,785 are incorporated herein byreference.

In FIGS. 3A-3C, cross-sectional views of exemplary portions offiltration media are shown wherein the fluted sheet has one or morenon-peak ridge extending along at least a portion of the flute length.FIG. 3A shows a fluted sheet having one non-peak ridge 81 providedbetween adjacent peaks 82, 83, and FIGS. 3B and 3C show fluted sheetshaving two non-peak ridges 84, 85 between adjacent peaks 86, 87. Thenon-peak ridges 81, 84, 85 can extend along the flute length any amountincluding, for example, an amount of 20% of the flute length to 100% ofthe flute length. In addition, the fluted sheet can be provided withoutnon-peak ridges 81, 84, 85 between all adjacent peaks 82, 83, 86, 87,and can be provided with differing numbers of non-peak ridges 81, 84, 85between adjacent peaks 82, 83, 86, 87 (e.g., alternating zero, one, ortwo non-peak ridges in any arrangement). The presence of non-peak ridges81, 84, 85 can help provide more media available for filtration in agiven volume, and can help reduce stress on the fluted sheet therebyallowing for a smaller radius at the peaks and therefore reduced mediamasking. Such media can be used in arrangements according to the presentdisclosure.

II. Manufacture of Coiled Media Configurations Using Fluted Media,Generally.

In FIG. 4, one example of a manufacturing process for making a mediastrip (single facer) corresponding to strip 1, FIG. 1 is shown. Ingeneral, facing sheet 64 and the fluted (corrugated) sheet 66 havingflutes 68 are brought together to form a media web 69, with an adhesivebead located there between at 70. The adhesive bead 70 will form asingle facer bead 14, FIG. 1.

The term “single facer bead” references a sealant bead positionedbetween layers of a single facer; i.e., between the fluted sheet andfacing sheet.

An optional darting process occurs at station 71 to form center dartedsection 72 located mid-web. The z-filter media or Z-media strip 74 canbe cut or slit at 75 along the bead 70 to create two pieces 76, 77 ofz-filter media 74, each of which has an edge with a strip of sealant(single facer bead) extending between the corrugating and facing sheet.Of course, if the optional darting process is used, the edge with astrip of sealant (single facer bead) would also have a set of flutesdarted at this location. The strips or pieces 76, 77 can then be cutacross, into single facer strips for stacking, as described below inconnection with FIG. 7.

Techniques for conducting a process as characterized with respect toFIG. 4 are described in PCT WO 04/007054, published Jan. 22, 2004incorporated herein by reference.

Still in reference to FIG. 4, before the z-filter media 74 is putthrough the darting station 71 and eventually slit at 75, it must beformed. In the schematic shown in FIG. 4, this is done by passing asheet of media 92 through a pair of corrugation rollers 94, 95. In theschematic shown in FIG. 4, the sheet of media 92 is unrolled from a roll96, wound around tension rollers 98, and then passed through a nip orbite 102 between the corrugation rollers 94, 95. The corrugation rollers94, 95 have teeth 104 that will give the general desired shape of thecorrugations after the flat sheet 92 passes through the nip 102. Afterpassing through the nip 102, the sheet 92 becomes corrugated across themachine direction and is referenced at 66 as the corrugated sheet. Thecorrugated sheet 66 is then secured to facing sheet 64. (The corrugationprocess may involve heating the media, in some instances.)

Still in reference to FIG. 4, the process also shows the facing sheet 64being routed to the darting process station 71. The facing sheet 64 isdepicted as being stored on a roll 106 and then directed to thecorrugated sheet 66 to form the Z-media 74. The corrugated sheet 66 andthe facing sheet 64 would typically be secured together by adhesive orby other means (for example by sonic welding).

Referring to FIG. 4, an adhesive line 70 is shown used to securecorrugated sheet 66 and facing sheet 64 together, as the sealant bead.Alternatively, the sealant bead for forming the facing bead could beapplied as shown as 70 a. If the sealant is applied at 70 a, it may bedesirable to put a gap in the corrugation roller 95, and possibly inboth corrugation rollers 94, 95, to accommodate the bead 70 a.

Of course the equipment of FIG. 4 can be modified to provide for thetack beads 20, if desired.

The type of corrugation provided to the corrugated media is a matter ofchoice, and will be dictated by the corrugation or corrugation teeth ofthe corrugation rollers 94, 95. One useful corrugation pattern will be aregular curved wave pattern corrugation, of straight flutes, as definedherein above. A typical regular curved wave pattern used, would be onein which the distance D2, as defined above, in a corrugated pattern isat least 1.2 times the distance D1 as defined above. In exampleapplications, typically D2=1.25-1.35×D1, although alternatives arepossible. In some instances the techniques may be applied with curvedwave patterns that are not “regular,” including, for example, ones thatdo not use straight flutes. Also, variations from the curved wavepatterns shown are possible.

As described, the process shown in FIG. 4 can be used to create thecenter darted section 72. FIG. 5 shows, in cross-section, one of theflutes 68 after darting and slitting.

A fold arrangement 118 can be seen to form a darted flute 120 with fourcreases 121 a, 121 b, 121 c, and 121 d. The fold arrangement 118includes a flat first layer or portion 122 that is secured to the facingsheet 64. A second layer or portion 124 is shown pressed against thefirst layer or portion 122. The second layer or portion 124 ispreferably formed from folding opposite outer ends 126, 127 of the firstlayer or portion 122.

Still referring to FIG. 5, two of the folds or creases 121 a, 121 b willgenerally be referred to herein as “upper, inwardly directed” folds orcreases. The term “upper” in this context is meant to indicate that thecreases lie on an upper portion of the entire fold 120, when the fold120 is viewed in the orientation of FIG. 5. The term “inwardly directed”is meant to refer to the fact that the fold line or crease line of eachcrease 121 a, 121 b, is directed toward the other.

In FIG. 5, creases 121 c, 121 d, will generally be referred to herein as“lower, outwardly directed” creases. The term “lower” in this contextrefers to the fact that the creases 121 c, 121 d are not located on thetop as are creases 121 a, 121 b, in the orientation of FIG. 5. The term“outwardly directed” is meant to indicate that the fold lines of thecreases 121 c, 121 d are directed away from one another.

The terms “upper” and “lower” as used in this context are meantspecifically to refer to the fold 120, when viewed from the orientationof FIG. 5. That is, they are not meant to be otherwise indicative ofdirection when the fold 120 is oriented in an actual product for use.

Based upon these characterizations and review of FIG. 5, it can be seenthat a regular fold arrangement 118 according to FIG. 5 in thisdisclosure is one which includes at least two “upper, inwardly directed,creases.” These inwardly directed creases are unique and help provide anoverall arrangement in which the folding does not cause a significantencroachment on adjacent flutes.

A third layer or portion 128 can also be seen pressed against the secondlayer or portion 124. The third layer or portion 128 is formed byfolding from opposite inner ends 130, 131 of the third layer 128.

Another way of viewing the fold arrangement 118 is in reference to thegeometry of alternating ridges and troughs of the corrugated sheet 66.The first layer or portion 122 is formed from an inverted ridge. Thesecond layer or portion 124 corresponds to a double peak (afterinverting the ridge) that is folded toward, and in preferredarrangements, folded against the inverted ridge.

Techniques for providing the optional dart described in connection withFIG. 5, in a preferred manner, are described in PCT WO 04/007054,incorporated herein by reference. Techniques for coiling the media, withapplication of the winding bead, are described in PCT application US04/07927, filed Mar. 17, 2004 and incorporated herein by reference.

Alternate approaches to darting the fluted ends closed are possible.Such approaches can involve, for example, darting which is not centeredin each flute, and rolling or folding over the various flutes. Ingeneral, darting involves folding or otherwise manipulating mediaadjacent to fluted end, to accomplish a compressed, closed state.

Techniques described herein are particularly well adapted for use inmedia packs that result from a step of coiling a single sheet comprisinga corrugated sheet/facing sheet combination, i.e., a “single facer”strip.

Coiled media pack arrangements can be provided with a variety ofperipheral perimeter definitions. In this context the term “peripheral,perimeter definition” and variants thereof, is meant to refer to theoutside perimeter shape defined, looking at either the inlet end or theoutlet end of the media pack. Typical shapes are circular as describedin PCT WO 04/007054 and PCT application US 04/07927. Other useableshapes are obround, some examples of obround being oval shape. Ingeneral oval shapes have opposite curved ends attached by a pair ofopposite sides. In some oval shapes, the opposite sides are also curved.In other oval shapes, sometimes called racetrack shapes, the oppositesides are generally straight. Racetrack shapes are described for examplein PCT WO 04/007054 and PCT application US 04/07927, each of which isincorporated herein by reference.

Another way of describing the peripheral or perimeter shape is bydefining the perimeter resulting from taking a cross-section through themedia pack in a direction orthogonal to the winding access of the coil.

Opposite flow ends or flow faces of the media pack can be provided witha variety of different definitions. In many arrangements, the ends aregenerally flat and perpendicular to one another. In other arrangements,the end faces include tapered, coiled, stepped portions which can eitherbe defined to project axially outwardly from an axial end of the sidewall of the media pack; or, to project axially inwardly from an end ofthe side wall of the media pack.

The flute seals (for example from the single facer bead, winding bead orstacking bead) can be formed from a variety of materials. In variousones of the cited and incorporated references, hot melt or polyurethaneseals are described as possible for various applications.

Reference numeral 130, FIG. 6, generally indicates a coiled media pack130. The coiled media pack 130 comprises a single strip 130 a of singlefacer material comprising a fluted sheet secured to facing sheet coiledaround a center, which can include a core, or which can be careless asillustrated. Typically, the coiling is with facing sheeting directedoutwardly. As previously described, in general a single facer bead andwinding bead would be used, to provide flute seals within the media.

The particular coiled media pack 130 depicted comprises an oval mediapack 131. It is noted that the principles described herein, however, canbe applied starting with the media pack having a circular configuration.

In FIG. 7, schematically there is shown a step of forming a stackedz-filter media pack from strips of z-filter media, each strip being afluted sheet secured to a facing sheet. Referring to FIG. 7, singlefacer strip 200 is being shown added to a stack 201 of strips 202analogous to strip 200. Strip 200 can be cut from either of strips 76,77, FIG. 4. At 205, FIG. 7, application of a stacking bead 206 is shown,between each layer corresponding to a strip 200, 202 at an opposite edgefrom the single facer bead or seal. (Stacking can also be done with eachlayer being added to the bottom of the stack, as opposed to the top.)

Referring to FIG. 7, each strip 200, 202 has front and rear edges 207,208 and opposite side edges 209 a, 209 b. Inlet and outlet flutes of thecorrugated sheet/facing sheet combination comprising each strip 200, 202generally extend between the front and rear edges 207, 208, and parallelto side edges 209 a, 209 b.

Still referring to FIG. 7, in the media pack 201 being formed, oppositeflow faces are indicated at 210, 211. The selection of which one offaces 210, 211 is the inlet end face and which is the outlet end face,during filtering, is a matter of choice. In some instances the stackingbead 206 is positioned adjacent the upstream or inlet face 211; inothers the opposite is true. The flow faces 210, 211, extend betweenopposite side faces 220, 221.

The stacked media pack 201 shown being formed in FIG. 7, is sometimesreferred to herein as a “blocked” stacked media pack. The term “blocked”in this context, is an indication that the arrangement is formed to arectangular block in which all faces are 90° relative to all adjoiningwall faces. Alternate configurations are possible, as discussed below inconnection with certain of the remaining figures. For example, in someinstances the stack can be created with each strip 200 being slightlyoffset from alignment with an adjacent strip, to create a parallelogramor slanted block shape, with the inlet face and outlet face parallel toone another, but not perpendicular to upper and bottom surfaces.

In some instances, the media pack will be referenced as having aparallelogram shape in any cross-section, meaning that any two oppositeside faces extend generally parallel to one another.

It is noted that a blocked, stacked arrangement corresponding to FIG. 7is described in the prior art of U.S. Pat. No. 5,820,646, incorporatedherein by reference. It is also noted that stacked arrangements aredescribed in U.S. Pat. Nos. 5,772,883; 5,792,247;

U.S. Provisional 60/457,255 filed Mar. 25, 2003; and U.S. Ser. No.10/731,564 filed Dec. 8, 2003. All four of these latter references areincorporated herein by reference. It is noted that a stacked arrangementshown in U.S. Ser. No. 10/731,504, is a slanted stacked arrangement.

III. Example Air Cleaner and Components, FIGS. 8-34

A. Overview of Air Cleaner and Components, FIGS. 8-10

On embodiment of an air cleaner is depicted in FIGS. 8-10 at referencenumeral 300. In the one shown, the air cleaner 300 includes a housing302, an inlet arrangement 304, and an outlet arrangement 306. In thisembodiment, the inlet arrangement 304 and the outlet arrangement 306 areat opposite ends of the housing 302.

The housing 302 includes a surrounding housing-wall 308 defining an openinterior 310. The housing 302 further defines an access opening 312 incommunication with the open interior 310. In the embodiment shown, theaccess opening 312 is located between the inlet arrangement 304 and theoutlet arrangement 306. When the air cleaner 300 is in a normal, uprightoperable orientation, the access opening 312 will be at a top part ofthe air cleaner 300.

A cover 314 is removably secured to the housing 302 over the accessopening 312. In this embodiment, the cover 314 is pivotably secured tothe housing 302 by a hinge arrangement 316 located adjacent to theoutlet arrangement 306. In this manner, the cover 314 is allowed topivot about the hinge arrangement 316 between a closed position (FIGS. 8and 10) and an open position (FIG. 9). When in the open position, theinterior 310 may be accessed. Further features regarding the cover 314are discussed below in section E.

In the embodiment shown in FIGS. 8-10, the housing-wall 308 defines apair of opposing receiving grooves 318, 319. Each of the grooves 318,319 is in open communication with the access opening 312 and is locatedcloser to the outlet arrangement 306 then to the inlet arrangement 304.In FIG. 9, the receiving groove 319 can be seen in the interior 310 ofthe housing 302. The receiving groove 318 is a mirror-image of thegroove 319. In FIGS. 8 and 9, only the exterior of the receiving groove318 is visible. The receiving grooves 318, 319 help to orient a filtercartridge and cassette assembly 320 into operable orientation andsealing engagement with the housing 302.

In FIG. 9, one embodiment of the filter cartridge and cassette assembly320 can be seen removed from the housing 302. The cartridge and cassetteassembly 320 includes a filter cartridge 322 removably oriented in acassette 324. The filter cartridge and cassette assembly 320 is operablyoriented for selective removal within the open interior 310 between theinlet arrangement 304 and the outlet arrangement 306.

The filter cartridge 322 includes z-media 326 as described in sections Iand II, above. In FIG. 9, only a portion of the z-media 326 isillustrated, but it should be understood that the entire face of thecartridge 322 would have z-media 326 as illustrated at 326 a. Thecartridge 322 includes a seal member 328, which forms a releasable sealwith a sealing surface in the housing 302. More details regarding thefilter cartridge 322 and seal member 328 are discussed below in sectionB.

The cassette 324 includes a surrounding cassette-wall 330. Thecassette-wall 330 defines an open interior volume 332 (FIG. 26)therewithin. The interior volume 332 is sized to receive the filtercartridge 322 therewithin.

The cassette 324, in this embodiment, further includes a plurality oflugs extending therefrom. In the embodiment shown, there is depictedfirst and second lugs 334, 335 (FIG. 27). When the cartridge andcassette assembly 320 is operably oriented within the housing 302, eachlug of the plurality of lugs in positioned in the receiving grooves. Inthe embodiment shown, the first and second lug 334, 335 is eachpositioned within a respective one of the receiving grooves 318, 319.This positioning of the lugs 334, 335 within the grooves 318, 319 willhelp the person installing assembly 320 to properly orient the assembly320 into sealing engagement with the housing 302. This is discussedfurther below in sections E and F.

When operably installed, at least a portion of the filter cartridge 322is removably oriented in the interior volume 332 of the cassette 324.The inlet flow face 336 is located adjacent to a first open end 338 ofthe cassette 324, and the seal member 328 is outside of the cassette 324and adjacent to a second open end 340 of the cassette 324.

In FIG. 9, there is also depicted an optional safety element 342. Thesafety element 342 is removably sealed between the filter cartridge 322and the outlet arrangement 306. More details about one exampleembodiment of safety element 342 is discussed in section D below.

FIG. 10 illustrates the air cleaner 300 in operation. Air to befiltered, such as air being drawn in to an engine enters the air cleaner300 illustrated by arrow 344. The air goes through the inlet arrangement304, which in this embodiment, functions as a pre-cleaner 458 (whichwill be discussed further below in section E). The air then flows fromthe inlet arrangement 304, through the inlet flow face 336 of thecartridge 322, then through the z-media 326, and then exits thecartridge 322. From there, the air flows through the safety element 342and then through the outlet arrangement 306. The air exits the aircleaner 300 as shown by arrow 346 in FIG. 10. From there, the filteredair is used for downstream equipment, such as an engine.

With this overview, we now turn to a description of example embodimentsof the components and operation.

B. Example Filter Cartridge, FIGS. 11-20

In reference now to FIGS. 11-20, an example of embodiment of filtercartridge 322 is illustrated. FIG. 11 shows an exploded, perspectiveview of one example embodiment of the filter cartridge 322, which can beutilized in the air cleaner 300. Other embodiments are possible, butthis is one usable embodiment that can be used, to advantage. However,it is not a requirement that the filter cartridge have all components orfeatures. The individual features, techniques, and advantages can beselected and be selectively combined for various alternate arrangements.

In the embodiment depicted, the filter cartridge 322 includes a mediapack 350 having first and second opposite flow faces 351, 352. The mediapack 350 comprises z-media 326, as described above in Sections I and II.In this embodiment, the first flow face 351 (FIG. 12) also correspondsto the inlet flow face 336. The second flow face 352 corresponds to anoutlet flow face 337. The z-media 326 is depicted schematically in theFIGS., and the individual flutes are only shown across a portion of thefirst and second flow faces 351, 352. It should be understood that theentire first and second flow faces 351, 352 include fluted z-media 326.

In the embodiment shown, the media pack 350 comprises a stack of strips354 of single facer filter media material 355 (FIG. 11). Each strip 354includes a fluted media sheet 356 secured to a facing media sheet 357and oriented with flutes of each fluted sheet 356 extending in adirection between the first and second opposite flow faces, 351, 352.See FIG. 1, and the accompanying description above, for furtherexplanation of the fluted sheet and facing sheet.

The media pack 350, in this embodiment, is shaped such that the firstflow face 351 and the second flow face 352 each has a rectangularperimeter shape. As can be seen in FIG. 11, the media pack 350 has agenerally rectangular cross section, such that the overall shape of themedia pack 350 is rectangular. In this embodiment, the media pack 350has first and second opposite sides, 358, 359 extending between thefirst and second flow faces 351, 352.

As can also be seen in FIGS. 11, 12, and 15, this embodiment of themedia pack 350 further includes third and fourth opposite sides 360, 361extending between the first and second opposite flow faces 351, 352. Thethird and fourth sides 360, 361 also extend between the first and secondsides 358, 359.

Preferably, each strip 354 of the single facer filter media material hasfacing sheet 357 that is non-fluted, preferably flat. When arranged inthe manner shown, the media pack 350 comprises a plurality of flutesextending in a direction between the inlet flow face 336 and the outletflow face 337. Selected ones of the flutes are closed at the inlet flowface 336 while being open at the outlet flow face 337, while selectedones of other flutes are open at the inlet flow face 336 and closed atthe outlet flow face 337. When constructed this way, the media pack 350is closed to air entering the inlet flow face 336 and passing outwardlyfrom the outlet flow face 337 without being forced to filter flowthrough the z-media 326 of the media pack 350.

In the embodiment shown, the filter cartridge 322 further includes afirst side panel 362 secured to the first side 358 of the media pack350. Similarly, there is a second side panel 363 secured to the secondside 359 of the media pack 350. The first and second panel 362, 363 aresecured to the media pack 350 at the first and second sides 358, 359 inorder to close or otherwise seal what might be a leak-path forunfiltered air. The first and second side panels 362, 363 may be madefrom urethane, and the media pack 350 can be secured to the sides 358,359 by way of directly molding the media pack 350 into urethane thatresults in the panels 362, 363. Alternate methods can be used, such asby adhesive or other types of securing or molding techniques. As can beseen in FIG. 11, the first and second side panels 362, 363 are sized andshaped to match the shape of the first and second sides 358, 359. Inthis embodiment, they are rectangular in shape.

The filter cartridge 322, in the embodiment shown, further includes aframe 366. The frame 366 is depicted as mounted on the second flow face352 of the media pack 350. Referring now to FIGS. 17-20, the frame 366includes a base member 368. The base member 368 defines an air flowopening arrangement 370 in air flow communication with the second flowface 352.

The frame 366, in this embodiment, further includes a seal supportsection 372 extending from the base member 368 along a perimeter 373 ofthe air flow opening arrangement 370. The seal support section 372 isfor supporting the seal member 328, as will be described further below.

The base member 368, in this embodiment, has first and second oppositeedges 375, 376. Extending between the first and second opposite edges,375, 376 are third and fourth opposite edges 377, 378. As can be seen inFIGS. 17 and 18, in this example embodiment, the edges 375-378 form agenerally rectangular structure. In the particular preferred embodimentdepicted, the third and fourth edges 377, 378 are structure-free; thatis, there are no other edges, flanges, or other structure dependingtherefrom.

In the embodiment depicted, the frame 366 further includes first andsecond opposite spaced blades 380, 381 extending from the base member368 and in a different direction from the base member 368 as the sealsupport section 372. That is, in this embodiment, the first and secondblades 380, 381 extend from the base member 368 in a direction towardthe media pack 350, while the seal support section 372 extends from thebase member 368 in a direction away from the media pack 350. In theembodiment shown, the first and second blades 380, 381 extend from thefirst and second edges 375, 376 of the base member 368. Preferably, andin the embodiment shown, the first and second blades 380, 381 areconnected together only by an intervening portion of the base member368. That is, there is no other structure that connects the first andsecond blades 380, 381. As such, in this embodiment, the first andsecond blades 380, 381, are generally parallel to each other and extendbetween the third and fourth edges 377, 378.

Turning now to FIG. 15, one of the purposes of the first and secondblades 380, 381 can be appreciated. In this arrangement, the first andsecond blades, 380, 381 are embedded within the media pack 350 throughthe second flow face 352, which corresponds to the outlet flow face,337. Embedding the first and second blades 380, 381, within the mediapack 350 can be helpful when manufacturing the filter cartridge 322. Thefirst and second blades 380, 381 are embedded sufficiently far to helpsecure the frame 366 in place on the media pack 350 before the otherstructure (such as the first and second side panels 362, 363 and theseal member 328) are added. It is convenient to have the first andsecond blades 380, 381 be sufficiently long to hold the frame 366 inplace on the media pack 350. For example, the first and second blades380, 381 each has a length extending from the base 368 of at least 5 mm.The length of the first and second blades 380, 381 does not have to beso long that it may interfere with the filtering function. For example,the first and second blades 380, 381 will have a length extending fromthe base 368 no greater than 30 mm.

When the media pack 350 comprises a stack of strips 354 of single facerfilter media material 355, such as in the example depicted, then thefirst and second blades 380, 381 can be used to extend from the basemember 368 and between adjacent strips 354 (FIG. 11) of the single facerfilter media material 355. As can be seen in FIG. 15, the first blade380 will have at least one strip 354 of single facer filter mediamaterial 355 between it and the fourth side 361 of the media pack 350.It may also have more than one strip 354 between it and the fourth side361. Similarly, the second blade 381 will have at least one strip 354between it and the third side 360, although it may have more than onestrip 354 between it and the third side 360.

Preferably, the first and second blades 380, 381 will have a relativelythin cross-sectional thickness so that it may be easily accommodatedbetween adjacent strips 354 of the single facer media material 355. Forexample, the first and second blades 380, 381 each has a cross-sectionalthickness of no greater than 4 mm.

In this embodiment, the frame 366 further includes a media facecross-piece arrangement 382 in engagement with the base member 368. Inthe embodiment shown, the cross-piece arrangement 382 is depicted as agrid 384 forming a pattern of diamond-shapes. The grid 384 helps to holdthe media pack 350 in place, and can help to prevent telescoping of themedia pack 350.

In this embodiment, the filter cartridge 322 includes the seal member328 oriented against the seal support section 372. This can be seen in,for example, FIG. 15. While a variety of embodiments can be used, inthis embodiment, the seal member 328 includes a portion 386 a (FIG. 16)positioned against an exterior surface 386 (FIG. 20) of the seal supportsection 372; an exterior surface 387 of the base member 368; a portion388 (FIG. 14) of the first side panel 362; and a portion 389 (FIG. 14)of the second side panel 363. The seal member 328 correspondinglyincludes portions 387 a, 388 a, and 389 a which are against the surfaces387, 388, and 389.

When formed like this, the seal member 328 can be over-molded to theframe 366 and the media pack 350. That is, in one example ofmanufacturing the media pack 350, the frame 366 will be secured to themedia pack 350 by embedding the first and second blades 380, 381 withinthe media pack 350. Next, the first and second side panels 362, 363 aresecured to the first and second sides 358, 359. Finally, the seal member328 is over-molded so that it goes over the seal support section 372,and against the exterior surface 386, the exterior surface 387 of thebase member 368, the portion 388 of the first side panel 362 and theportion 389 of the second side panel 363. Note that the portions 388 a,389 a only extend a small fraction of the length of the first and secondsides 358, 359. In this case, they do not extend much further than thelength of the first and second blades 380, 381. For example, they mayextend a length of at least 5 mm and no greater than 30 mm.

As can also be seen in the view of FIG. 15, the seal member 328 includesa portion 390 a which extends over a portion 390 of third side 360 and aportion 391 a which extends over a portion 391 of the fourth side 361.The portions 390 a, 391 a only extend a relatively small length alongthe third and fourth sides 360, 361, for example, less than 10% of thelength. As can be seen in FIG. 15, the portions 390 a, 391 a can have alength similar to the length of the first and second blades 380, 381.These portions 390 a, 391 a, in this embodiment, directly attach to thethird and fourth sides, 360, 361 of the media pack 350. This is at leastbecause the frame 366 is open or structure-free along the third andfourth edges 377, 378.

As can be seen in FIGS. 14-16, in this embodiment, the seal member 328has an outer peripheral surface 392 configured to form a radiallyoutwardly directed seal 394 (FIGS. 31 and 32) with the air cleanerhousing 302. The seal 394 is preferably an outwardly directed radialseal 464. The seal member 328 forms the seal 464 by compression of theseal member 328 between and against the exterior surface 386 of the sealsupport section 372 and an internal sealing surface 462 within the aircleaner housing 302.

In reference now to FIGS. 16 and 16 a, an outer profile of the sealmember 328 is shown in detail. A sealing portion 396 is along the outerperipheral surface 392. In the embodiment shown, it is generallyradially inwardly of the frame contact section forming portions 388,389. Between the sealing portion 396 and the frame-contacting portions388, 389, there is an inward step 398.

The seal support section 372 defines an end tip 400. In this embodiment,the seal member 328 includes a portion 402 that is positioned over theend tip 400.

C. Cartridge and Cassette Assembly, FIGS. 21-28

In reference now to FIGS. 21-28, the cartridge/cassette assembly 320 isdepicted. As mentioned above, the cassette 324 includes a cassettesurrounding wall 330 defining cassette open interior volume 332therewithin. As also mentioned above, the wall 330 includes first andsecond opposite open ends 338, 340 in communication with the interiorvolume 332.

In this embodiment, the cassette wall 330 has first and second oppositeside walls 404, 405, each defining an interior surface 406, 407 incommunication with the interior volume 332. The first and second sidewalls 404, 405 also define an opposite exterior surface 408, 409.

The cassette surrounding wall 330, in the embodiment shown, has arectangular cross-section and includes a third side wall 410 inextension between the first side wall 404 and the second side wall 405.

In the embodiment depicted, the cassette surrounding wall 330 furtherincludes a fourth side wall 411 extending between the first side wall404 and the second side wall 405. The fourth side wall 411, in theembodiment shown, is generally parallel to the third side wall 410.

As can be appreciated by reviewing FIGS. 21-23, the second open end 340is sized to be an access opening 412 to permit the filter cartridge 322to be operably inserted and removed from the interior volume 332 of thecassette 324.

At the first open end 338, there is at least one cross piece 414extending over the first open end 338 and in engagement with thecassette surrounding wall 330. The cross piece 414 in the embodimentshown, includes a grid arrangement 416. The grid arrangement 416 helpsto hold the filter cartridge 322 in place within the cassette 324, whilestill allowing for the passage of air flow through the first open end338 and to the inlet flow face 336 of the cartridge 322. In FIG. 23, itcan be seen how when the filter cartridge 322 is operably oriented inthe interior volume 332 of the cassette 324, the inlet flow face 336 isopposing, and may be against, the at least one cross piece 414 of thefirst open end 338 of the cassette 324. It can also be appreciated thatthe filter cartridge 322 is removably oriented within the interiorvolume 332 of the cassette 324, so that the seal member 328 is outsideof the cassette 324 and adjacent to the second open end 340 of thecassette 324. In the embodiment shown, the frame 366 is also outside ofthe cassette 324 when the cartridge 322 is operably oriented within thevolume 332 of the cassette 324. As such, in the example illustrated,only at least a portion of the filter cartridge 322 is removablyoriented in the interior volume 332 of the cassette 324.

As mentioned above in section A, in this example embodiment, thecassette 324 includes a plurality of lugs. In the embodiment depicted,there are first and second lugs 334, 335. In the embodiment shown, thefirst lug 334 extends from the exterior surface 408 of the first sidewall 404. In this example, the second lug 335 extends from the exteriorsurface 409 of the second side wall 405. In this embodiment, the firstand second lugs 334, 335 are embodied as projecting cylinders, withcircular cross-sections. The first and second lugs 334, 335 project fromthe first and second side walls 404, 405 a distance of at least 5 mm,for example 10-40 mm, and no greater than 100 mm. In someimplementations, there are no more than two lugs used (the first lug 334and second lug 335).

As can be seen in FIGS. 21, 22, and 25-27, in this embodiment, the firstand second lug 334, 335 is each located adjacent to the second open end340 of the cassette 324. Further, the first and second lugs 334, 335 inthis embodiment, is each located adjacent to the third side wall 410. Bythe term “adjacent” in this context, it is meant that the first andsecond lugs 334, 335 are located no greater than 20% of the overalllength from the edge of the second open end 340 and no greater than 20%of the overall length of the first and second side walls 404, 405 fromthe third side wall 410.

In the embodiment depicted, the cassette 324 further includes a handle418 sized to accommodate at least a portion of a human hand. The handle418 is provided so that the user may have structure to grasp in order tomanipulate the cassette 324 alone, and also the cartridge/cassetteassembly 320.

In the embodiment shown, the handle 418 is projecting from thesurrounding wall 330. The handle 418, in this embodiment, includes aflange 420 connected to the surrounding wall 330 by gussets 422. Byspacing the flange 420 from the cassette surrounding wall 330, space isprovided to accommodate portions of a human hand, such as 4 fingers. Theflange 422 can be spaced at least 5 mm, for example 10-75 mm from thesurrounding wall 330.

While a variety of embodiments are possible, in the particular oneillustrated, the handle 418 projects from the third side wall 410.Further, in the one depicted, the handle 418 is adjacent to the firstopen end 338 of the cassette 324. By the term “adjacent” it is meantthat the handle 420 is no greater than 20% of the overall length of thethird side wall 410 away from the first open end 338.

D. Example Safety Element, FIG. 29

As mentioned in section A, above, the air cleaner 300 may include safetyelement 342. One example embodiment of safety element 342 is illustratedin FIG. 29. In this embodiment, the safety element 342 includes a mediapack of pleated filter media 424. The media pack 424 is circumscribed bya safety frame 426. In this embodiment, the frame 426, as well as theoverall safety element 342 is rectangular.

The safety element 342 includes a seal member 428 around an outerperimeter 429 of the frame 426. The seal member 428 forms a seal (FIGS.31 and 32) with the housing-wall 308 of the housing 302. In thisexample, the seal 430 is a radial seal 431.

The safety element 342 is removably sealed between the filter cartridge322 and the outlet arrangement 306, as can be seen in FIGS. 31 and 32.

In this embodiment, the safety element 342 is constructed and arrangedto be pivotably mounted within the air cleaner housing 302. In theexample shown, the safety element 342 includes a pivot member 432 whichis received within a pivot catch 434 (FIG. 32) of the housing 302.

In use, the safety element 342 can be mounted for operable use withinthe air cleaner 300 by orienting the pivot member 432 within the pivotcatch 434 in the housing wall 308. The element 342 is then rotated orpivoted about the pivot member 432 in a direction toward the outletarrangement 306 to slide the seal member 428 into sealing engagement toform radial seal 431 with the housing-wall 308.

In the example illustrated, this embodiment of the safety element 342also includes a projecting safety element handle 436. The safety elementhandle 436 is preferably part of the safety frame 426 and projects fromthe inlet flow face 438 of the pleated media 424. The handle 436includes a gripper 440 that extends projecting away from the inlet flowface 438, to provide an open volume between the gripper 440 and themedia 424. As such, the gripper 440 can be grasped with a human hand,and the volume between the gripper 440 and the inlet flow face 438 willaccommodate one or more fingers of a human hand. This will allow thesafety element 342 to be handled and manipulated. For example, thehandle 436 can be grasped when removing the safety element 342 from theair cleaner housing 302.

E. Example Air Cleaner and Components, FIGS. 8-10 and 30-34

Section A, above, provides an overview of the air cleaner 300 andexample embodiments of various usable components. This section providesfurther detail on the air cleaner 300.

As mentioned above, the housing wall 308 includes grooves 318, 319. Ascan be seen in FIG. 9, the grooves 318, 319 each have a straight,vertical wall 442, a bottom bight section 444, and a generally slopedwall 446 extending from the bight section 444 and to the access opening312. The grooves 318, 319 receive the first and second lugs 334, 335when installing the cartridge/cassette assembly 320. The lugs 334, 335will rest in each respective bight 444, and the cartridge/cassetteassembly 320 can be rocked about the pivot point created between thefirst and second lugs 334, 335 in the respective bights 444, in order torock or pivot the cartridge/cassette assembly 320 into sealingengagement with the housing 302. The person installing thecartridge/cassette assembly 320 can grasp the handle 418 of the cassette324 in order to rock the cartridge/cassette assembly 320 into operablysealing engagement.

As can be seen in FIG. 9, each of the receiving grooves 318, 319 islocated adjacent to the outlet arrangement 306.

The cover 314, in the embodiment shown, includes a grip 448 projectingfrom a remaining portion of the cover 314 and extending over a portionof the inlet arrangement 304. The grip 448, as can be seen in FIG. 34,includes ribs 450 to help enhance the grip 448. In use, a personsfingers would contact the ribs 450 while a remaining portion of the handis curled around an end portion 452 (FIG. 34) of the grip 448.

The cover 314 has an exterior surface 454 and an opposite interiorsurface 455. The interior surface 455 faces the housing open interior310. In the particular embodiment shown, the interior surface 455includes a receiver 456 that is sized to receive the cassette handle418. When the cartridge/cassette assembly 320 is operably orientedwithin the housing 302, the receiver 456 contains at least a portion ofthe cassette handle 418 when the cover 314 is secured over the accessopening 312. FIG. 31 shows the cassette handle 418 projecting within andbeing received by the receiver 456.

The inlet arrangement 304, in the embodiment shown, includes apre-cleaner 458. In this embodiment, the pre-cleaner 458 includes aplurality of centrifugal separator tubes 460. The tubes 460 causeincoming air to swirl around and helps to separate and removeparticulate matter from the incoming air before the air is drawn into aremaining portion of the air cleaner 300.

As can be seen in FIGS. 31 and 32, the seal 394 formed between thefilter cartridge 322 and a sealing surface 462 of the housing-wall 308is radial seal 464.

An indicator 468, such as a restriction indicator or a mass air flowsensor is provided downstream of the safety element 342 to insure airflow before the air exit through the outlet arrangement 306. Thisindicator 468 helps to provide information on the cartridge 322, such asthe amount of restriction across it.

F. Example Methods

The air cleaner 300 can be used in a method for cleaning air. In such amethod, air to be filtered enters the air cleaner housing 302 at theinlet arrangement 304. At that point, the air enters the pre-cleaner458. The air passes into individual cyclonic or centrifugal separatorsshown as tubes 460 in the pre-cleaner 458. The centrifugal separatortubes 460 can be those as described in, for example, U.S. Pat. Nos.4,242,115 and 4,746,340, each incorporated by reference herein. Thepre-cleaner 458 separates dust or other particulate material, and thedust separated at this location is ejected from the pre-cleaner 458through a dust ejector 466 (FIG. 31). The pre-cleaner 458 causes dustseparation through centrifugal or cyclonic process, as opposed to aprocess of passing the air through filter media.

From the pre-cleaner 458, the air flows downstream and to the filtercartridge 322. From there, the air is cleaned or filtered by flowingthrough the inlet flow face 336, into the fluted media pack 350 and thenout of the filter cartridge 322 by exiting through the outlet flow face337. The air is not allowed to bypass the filter cartridge 322 becauseof the radial seal 464 that is formed between the filter cartridge 322and the sealing surface 462 of the housing 302.

From the filter cartridge 322, the filtered air flows through the safetyelement 342 by passing through the inlet flow face 438 of the pleatedmedia 424. The air then exits the safety element 342 and passes throughthe outlet arrangement 306. From there, the filtered air is used bydownstream equipment, such as a diesel engine.

Periodically, it will be necessary to service the air cleaner 300. Toservice the air cleaner 300, the filter cartridge 322 will need to beremoved and replaced with a new filter cartridge 322. To do so, first, anew filter cartridge 322 is provided. The filter cartridge 322 willinclude media pack 350 having opposite inlet and outlet flow faces 336,337. The media pack 350, comprises a plurality of flutes extending in adirection between the inlet flow face 336 and the outlet flow face 337.The media pack 350 is closed to air entering the inlet face 356 andpassing outwardly from the outlet flow face 337 without filtering flowthrough the media of the media pack 350. Seal member 328 is secured tothe media pack 350.

Next, cassette 324 is provided. The cassette 324 includes cassettesurrounding wall 330, first and second lugs 334, 335 projecting from anexterior portion 408, 409 of the cassette wall 330, and cassette handle418 extending from the cassette wall 330.

Next, the filter cartridge 322 is oriented partially into the interiorvolume 332 of the cassette 324 so that the seal member 328 is outside ofthe cassette 324 to provide the filter cartridge/cassette assembly 320.

Next, the filter cartridge and cassette assembly 320 is oriented intothe access opening 312 in the air cleaner housing 302. The accessopening 312 is between the inlet arrangement 304 and the outletarrangement 306. While orienting the filter cartridge and cassetteassembly 320 into the access opening 312, the first and second lugs 334,335 are oriented into respective receiving grooves 318, 319 in thehousing 302 adjacent to the air cleaner outlet arrangement 306.

Next, the cassette handle 418 is grasped to move the filter cartridgeand cassette assembly 320 so that the seal member 328 is urged againstthe sealing surface 462 in the housing 302 to form releasable seal 394.This can be done by rocking the assembly 320 about the lugs 334, 336 inthe grooves 318, 319 while holding the handle 418 to move the assembly320 in place to form radial seal 464.

IV. The Embodiment of FIGS. 37-46

A. Overview

Turning now to FIGS. 37-46, another embodiment of an air cleaner isshown generally at 550. The air cleaner 550 includes a housing 552, aninlet arrangement 554, and an outlet arrangement 556. The inletarrangement 554 and outlet arrangement 556 are depicted in thisembodiment as being at opposite ends of the housing 552.

The housing 552 includes a surrounding housing wall 558 defining an openinterior 560. The housing 552 further defines an access opening 562 incommunication with the open interior 560 (FIG. 38). In the embodimentshown, the access opening 562 is located between the inlet arrangement554 and outlet arrangement 556. When the air cleaner 550 is in a normal,upright operable orientation, the access opening 562 will be at a toppart of the air cleaner 550.

A cover 564 is provided. The cover 564 is removably secured to thehousing 552 over the access opening 562. In this embodiment, as with theprevious embodiment, the cover 564 is pivotably secured to the housing552 by a hinge arrangement 566. In this embodiment, the hingearrangement 566 is located adjacent to the outlet arrangement 556. Assuch, the cover 564 is allowed to pivot about the hinge arrangement 566between a closed position (FIG. 37) and an open position (FIG. 38). Whenin the open position, the interior 560 may be accessed. Further featuresregarding the cover 564 are discussed below.

In the previous embodiment, the housing wall 308 defined pair ofopposing receiving grooves 318, 319. In this embodiment, the housingwall 558 does not include such receiving grooves and is groove-free byhaving a groove free wall 558.

Still in reference to FIG. 37, as with the previous embodiment, in thisembodiment, the inlet arrangement 554 includes a pre-cleaner 568. Thepre-cleaner 568 includes a plurality of centrifugal separator tubes 570.The tubes 570 cause incoming air to swirl around and help to separateand remove particulate material from the incoming air before the air isdrawn into a remaining portion of the air cleaner 550. An ejector tube572 can be seen in FIG. 37, in which the particulate matter separated bythe pre-cleaner 568 may be expelled from the air cleaner 550.

In FIG. 38, an indicator 574, such a restriction indicator or a mass airflow sensor, is provided downstream of safety element 342. The indicator574 provides information, such as the amount of restriction within theair cleaner 550. The safety element 342 is as described above withrespect to FIG. 29.

B. Filter Cartridge

In FIG. 38, a filter cartridge 578 can be seen removed from the housing552. Unlike previous embodiments, this embodiment does not include acassette. Rather, the filter cartridge 578 is placed directly into thehousing 552 without the use of a cassette; hence, the filter cartridge578 is cassette-free. The filter cartridge 578 is operably oriented forselective removal within the open interior 560 between the inletarrangement 554 and the outlet arrangement 556.

The filter cartridge 578 includes z-media 580 as described in sections Iand II, above. In FIG. 38, only a portion of the z-media 580 isillustrated, but it should be understood that the entire face 582 of thecartridge 578 would have z-media 580 as illustrated at 580 a. Thecartridge 578 includes a seal member 584, which forms a releasable sealwith the housing 552. As with the previous embodiment, in thisembodiment, the seal member 584 forms a radial seal 618 with an internalsurface 586 of the housing wall 558.

In reference now to FIGS. 41 and 42, example embodiment of thecassette-free filter cartridge 578 is depicted. The filter cartridge 578includes a media pack 588 having first and second opposite flow faces589, 590. In this embodiment, the first flow face 589 corresponds to aninlet flow face 591, while the second flow face 590 corresponds to anoutlet flow face 592.

In this embodiment, the media pack 588 comprises a stack of strips ofsingle facer filter media, as described above in connection with FIGS. 1and 11. In this embodiment, the media pack 588 is shaped such that thefirst flow face 589 and the second flow face 590 each has a rectangularperimeter shape. The media pack 588, in the embodiment shown, has agenerally rectangular cross-section with first and second opposite sides594, 595 extending between the first and second flow faces 589, 590. Themedia pack 588 further includes third and fourth opposite sides 596, 597(shown in phantom, FIG. 42) extending between the first and second flowfaces 589, 590. The third and fourth sides 596, 597 also extend betweenthe first and second sides 594, 595.

The media pack 588 comprises a plurality of flutes extending in adirection between the inlet flow face 591 and the outlet flow face 592.Selected ones of the flutes are closed at the inlet flow face 591 whilebeing open at the outlet flow face 592 (outlet flutes), while selectedones of other flutes are open at the inlet flow face 591 (inlet flutes)and closed at the outlet flow face 592. When constructed this way, themedia pack 588 is closed to air entering the inlet flow face 591 andpassing outwardly from the outlet flow face 592 without being forced tofilter flow through the z-media 580 of the media pack 588.

In this embodiment, the filter cartridge 578 further includes a firstside panel 602 secured to the first side 594 of the media pack 588.Similarly, there is a second side panel 603 secured to the second side595 of the media pack 588. The first and second panels 602, 603 aresecured to the media pack 588 at the first and second sides 594, 595 inorder to close or otherwise seal what might be a leak path forunfiltered air. The first and second side panels 602, 603 may be madefrom urethane, and the media pack 588 can be secured to the side panels602, 603 by way of directly molding the media pack 588 into urethanethat results in the panels 602, 603. Other methods can be used, such asby adhesive or other types of securing or molding techniques. The firstand second side panels 602, 603 are sized and shaped to match the shapeof the first and second sides 594, 595. In this embodiment, they arerectangular in shape.

The filter cartridge 578, in this embodiment, further includes a shell604. The shell 604 (FIGS. 43-45) is mounted on the media pack 588. Inthis embodiment, the shell 604 has first and second opposing shell walls606, 607 that are secured to and against the media pack 588.Specifically, in the embodiment shown, the first shell wall 606 issecured to and against the third side 596, while the second shell wall607 is secured to and against the fourth side 597.

In this embodiment, the shell 604 further includes a frame 608. In theembodiment depicted, the frame 608 extends between and joins the firstand second shell walls 606, 607. The frame 608 is mounted against thesecond flow face 590. The frame 608 includes a base member 610, whichdefines an air flow opening arrangement 612 in air flow communicationwith the second flow face 590. The frame 608, in this embodiment,further includes a seal support section 614. The seal support section614, as depicted, extends from the base member 610 along a perimeter 616(FIG. 44) of the air flow opening arrangement 612. The seal supportsection 614 is for supporting the seal member 584.

The seal support section 614, in the embodiment shown, extends in anaxial direction that is generally parallel to the first and second sidepanels 602, 603, or the first and second shell walls 606, 607, and inpreferred embodiments will extend in a same direction as the directionof flutes of the z-media 580.

The seal member 584 can be made out of a compressible material, forexample, urethane, or foamed polyurethane, or rubber. The seal member584 can be secured to the seal support section 614 using a variety oftechniques. Example techniques include securing it with adhesive orglue, or by molding onto the seal support section 614 such as byover-molding. When mounted onto the seal support section 614, as shownin FIGS. 41 and 42, the seal member 584 forms a radially directed seal618. In the embodiment shown, the radially directed seal 618 isoutwardly directed, so that the seal 618 is formed by compression of theseal member 584 between and against the sealing surface 586 (FIG. 38)and the seal support section 614 of the filter cartridge 578.

The seal member 584, in the embodiment shown, has a profile with atleast one step 620 that is larger in outermost dimension than the endtip 622 of the seal member 584. This helps to orient the seal member 584against the sealing surface 586 during installation.

One example of a useable seal member is described in U.S. Pat. No.6,350,291, incorporated herein by reference in its entirety.

As can be seen in the embodiment of FIGS. 41 and 45, the seal supportsection 614 has a smaller outermost dimension than the outermostdimension of the base member 610. Between the base member 610 and theseal support section 614 is an inwardly directed step 624.

The base member 610 defines opposite first and second edges 626, 627extending between the first and second shell walls 606, 607. The firstedge 626 is adjacent to the first side 594, while the second edge 627 isadjacent to the second side 595. In this embodiment, the first andsecond edges 626, 627 define a plurality of through-holes 628. Thethrough-holes 628 may be used to attach the first and second side panels602, 603 to the first and second sides 594, 595, particularly if thefirst and second side panels 602, 603 are molded directly to the mediapack 588. The holes 628 would receive the flow of uncured urethane, forexample, to help secure the first and second side panels 602, 603 inplace, if made in this manner.

The frame 608 further includes a media face cross-piece arrangement 630.In the embodiment shown, the cross-piece arrangement 630 is inengagement with the base member 610. In the embodiment shown, thecross-piece arrangement 630 is depicted as a grid 632. This embodimentshows the grid 632 as forming a pattern of diamond-shapes. The grid 632helps to hold the media pack 588 in place and can help to preventtelescoping of the media pack 588.

In this embodiment, the filter cartridge 578 further includes acartridge-handle 642. The cartridge-handle 642 projects from a portionof the media pack 588 to allow the filter cartridge 578 to be easilymanipulated by the user. In this embodiment, the cartridge-handle 642 ispart of the shell 604. In particular, the cartridge-handle 642 projectsfrom the first shell wall 606. The cartridge-handle 642 extends from thefirst shell wall 606 a sufficient distance to accommodate portions of ahuman hand between the cartridge-handle 642 and the first shell wall606. For example, the cartridge-handle 642 may accommodate 4 fingers ofa human hand, while the thumb is on the opposite side of thecartridge-handle 642.

C. Cover

Attention is directed to FIGS. 38-40 and 46, in which details of thecover 564 are shown. The cover 564, in the embodiment shown, includes agrip 634 projecting over the inlet arrangement 554, and in particular,over the pre-cleaner 568. The grip 634 projects from a free end 636 ofthe cover 564. Opposite from the free end 636 is the hinge arrangement566. By grasping the grip 634, the cover 564 may be pivoted about thehinge arrangement 566 relative to the housing wall 558 to selectivelycover or expose the open interior 560.

The cover 564 has an exterior surface 638 and an opposite interiorsurface 639. The interior surface 639 faces the housing open interior560. In the particular embodiment shown, the interior surface 639includes a receiver 640 that is sized to receive the cartridge-handle642 projecting from the first shell wall 606. When the filter cartridge578 is operably mounted within the housing 552, the receiver 640contains at least a portion of the cartridge-handle 642 when the cover564 is secured over the access opening 562. FIG. 46 shows thecartridge-handle 642 projecting within and being received by thereceiver 640. The receiver 640 in this embodiment, is generally locatedadjacent to the hinge arrangement 566 and remote from the free end 636and grip 634.

In this embodiment, the cover 564 further includes a projectionarrangement 644. The projection arrangement 644 extends from theinterior surface 639 into the housing open interior 560, when the cover564 is secured over the access opening 562. In the embodiment shown, theprojection arrangement 644 is located between the inlet flow face 591 orfirst flow face 589 of the filter cartridge 578 and the housingsurrounding wall 558 to help hold the filter cartridge 578 in sealingengagement with the housing 552. This can be seen in FIG. 46. Inparticular, the projection arrangement 644 is between the first flowface 589 and a downstream portion of the pre-cleaner 568.

In the embodiment shown, the projection arrangement 644 includes atleast first and second legs 645, 646. The first and second legs 645, 646in this embodiment, extend from the cover 564, and for example, extendfrom the interior surface 639 of the cover 564. The first and secondlegs 645, 646, in the embodiment shown, do not extend the full length ofthe first flow face 589; rather, they extend less than 50%, and about5-30% of the length of the first flow face 589 or the inlet flow face591. The first and second legs 645, 646 help to prevent the radial seal618 from backing out or becoming dislodged from its sealing engagementdue to vibration, for example.

In the embodiment shown, the receiver 640 is located between the firstand second legs 645, 646 and laterally spaced from the legs 645, 646.The legs 644, 645 are located adjacent to the free end 636 of the cover564, while the receiver 640 is located adjacent to the hinge arrangement566.

As can also be seen in FIGS. 38 and 46, the safety element 342 isoperably located between the outlet flow face 592 and the outletarrangement 556 of the housing 552. The safety element 342 is optional,and is removable and replaceable from the housing 552.

D. Method of Servicing

A method of servicing the air cleaner 550 is now described. The methodincludes grasping the cover 564 and pivoting the cover 564 away from thehousing 552. During this step of pivoting, there is a step of moving theprojection arrangement 644, which can include first and second legs 645,646, that are extending from the cover 564 from a position adjacent tothe filter cartridge 578. The step of moving the cover may also includeexposing the cartridge-handle 642 on the cassette-free filter cartridge578 from the receiver 640 in the cover 564. Next, the method includesgrasping the cartridge-handle 642 on the cassette-free filter cartridge578 and manipulating the filter cartridge 578 to release the seal, suchas radial seal 618, between the filter cartridge 578 and the housing 552by removing the cartridge 578 from the housing 552.

Next, a new cassette-free filter cartridge 578 is provided. Thecartridge-handle 642 on the new filter cartridge 578 is grasped anddirectly inserted (without a cassette) into the open interior 560 of thehousing 552. The new filter cartridge 578 is manipulated until the sealmember 584 forms seal 618 with the housing by, for example, compressionof the seal member 584 between and against the seal support section 614of the frame 608 and the sealing surface 586 of the housing surroundingwall 558.

Next, the cover 564 is closed. By closing the cover 564, the projectionarrangement 644 on the cover 564 is oriented between the inlet flow face591 and the housing 552. Specifically, the first and second legs 645,646 are oriented to project axially from the interior surface 639 of thecover 564 and be between the cartridge 578 and an internal surface ofthe housing wall 558. When closing the cover 564, the cartridge-handle642 is placed within the receiver 640 of the cover 564. This also helpsto secure the filter cartridge 578 within the housing 552.

V. The Embodiment of FIGS. 35-36, 47, and 48

In reference now to FIGS. 35 and 36, another embodiment of a cartridgeand cassette assembly is shown generally at 500. The cartridge/cassetteassembly 500 includes a filter cartridge 722, removably replaceablewithin a second embodiment of a cassette 502. The cassette 502 includesa cassette surrounding wall 504 defining a cassette open interior volume506 therewithin. The cassette surrounding wall 504 includes first andsecond opposite open ends 508, 510 in communication with the interiorvolume 506.

In this embodiment, the cassette surrounding wall 504 has first andsecond opposite side walls 512, 513 defining exterior surfaces 514, 515.As can be seen in FIG. 35, the first and second side walls 512, 513 aregenerally trapezoidal in shape by having inclined edges 516, 517.

The cassette surrounding wall 504, in the embodiment shown, has agenerally rectangular cross-section and includes a third side wall 518in extension between the first side wall 512 and the second side wall513. In this embodiment, the cassette surrounding wall 504 furtherincludes a fourth side wall 519 extending between the first side wall512 and the second side wall 513. The fourth side wall 519, in theembodiment shown, is generally parallel to the third side wall 518. Afirst and second side walls 512, 513 are generally parallel to eachother and perpendicular to the third and fourth side walls 518, 519. Aswith the previous embodiment, in this embodiment, the second open end510 is sized to be an access opening 520 to permit the filter cartridge722 to be operably inserted and removed from the interior volume 506 ofthe cassette 502.

At the first open end 508, there is at least one cross piece 522extending at least partially over the first open end 508 and inengagement with the cassette surrounding wall 504. The cross piece 522,in the embodiment shown, includes a ledge 524 extending over the firstopen end 508. Specifically, in this embodiment, the ledge 524 includesfirst and second arms 526, 527 extending over the first open end 508from the first and second side walls 512, 513, respectively. The ledge524 helps to hold the filter cartridge 722 in place within the cassette502, while still allowing for the passage of air flow through the firstopen end 508 and to the inlet flow face 736 of the cartridge 722. Whenthe filter cartridge 722 is operably oriented in the interior volume 506of the cassette 502, the inlet flow face 736 is opposing, and may beagainst, the ledge 524 including the first arm 526 and second arm 527.When the filter cartridge 722 is removably oriented within the interiorvolume 506 of the cassette 502, the seal member 728 is outside of thecassette 502 and adjacent to the second open end 510 of the cassette502. As such, as with the previous embodiment, only a portion of thefilter cartridge 722 is within the interior volume 506 of the cassette502.

As with the embodiment of FIGS. 8-34, in this embodiment, the cassette502 includes a plurality of lugs, which is depicted as first and secondlugs 530, 531. In the embodiment depicted, the first lug 530 extendsfrom the exterior surface 515 of the first side wall 512, and the secondlug 531 extends from the exterior surface 514 of the second side wall513. In the embodiment depicted, the first and second lugs 530, 531 areillustrated as being projecting cylinders with circular cross-sections.The first and second lugs 530, 531 project from the first and secondside walls 512, 513 a distance of at least 5 mm, for example, 10-40 mm,and no greater than 100 mm. In one example embodiment, the plurality oflugs includes no more than the first and second lugs.

The first and second lug 530, 531 is each located adjacent to the secondopen end 510 and adjacent to the inclined edges 516, 517. By the term“adjacent” in this context, it is meant that the first and second lugs530, 531 are located no greater than 20% of the overall length of theedge of the second open end 510, and no greater than 20% of the overalllength of the first and second side walls 512, 513 from the third sidewall 518.

As with the embodiment of FIGS. 8-34, in this embodiment the cassette502 further includes a handle 534 sized to accommodate at least aportion of a human hand. The handle 534 is provided so that the user mayhave structure to grasp in order to manipulate the cassette 502 alone,and also the cartridge/cassette assembly 500.

In this embodiment, the handle 534 is projecting from the surroundingwall 504. The handle 534 includes a flange 536 connected to thesurrounding wall 504 by gussets 538. By spacing the flange 536 from thecassette surrounding wall 504, space is provided to accommodate portionsof a human hand, such as four fingers. The flange 536 can be spaced atleast 5 mm, for example 10-75 mm from the surrounding wall 504.

In the illustrated embodiment, the handle 534 projects from the thirdside wall 518. Further, in the embodiment depicted, the handle 534 isadjacent to the first open end 508 of the cassette 502. By the term“adjacent” it is meant that the handle 534 is no greater than 20% of theoverall length of the third side wall 518 away from the first open end508.

The cartridge/cassette assembly 500 is selectively mountable within thehousing 302 (FIG. 8).

The filter cartridge 722 includes z-media 780 as described in sections Iand II, above. In FIGS. 35 and 47, only a portion of the z-media 780 isshown at portion 780 a. It should be appreciated that the entire inletface 736 and outlet face 737 would have z-media 780 as illustrated at780 a.

The filter cartridge 722 can be constructed analogously to the filtercartridge 578, described in connection with FIGS. 41 and 42. Onedifference between the filter cartridge 722 of FIGS. 35, 47, and 48 andthe filter cartridge 578 (FIGS. 41 & 42) is that the filter cartridge578 includes a cartridge-handle 642 constructed as part of the filtercartridge 578. Otherwise, the description of the filter cartridge 722 isthe same as the cartridge 578, described above, and this description isincorporated herein by reference. The filter cartridge 722 can include ashell 804 having a first shell wall 806 and a second shell wall 807.First and second side panels 802, 803 are against sides of the mediapack and are between the first and second shell walls 806, 807.

The shell 604 includes a frame, such as frame 608 including a sealsupport section, such as seal support section 614, and this supports theseal member 728. The seal member 728 forms a radially directed seal 818.A grid 832 is over and can be against the downstream or outlet flow face737.

The above provides examples and principles. Many embodiments can be madeusing the principles described.

What is claimed is:
 1. An air filter cartridge comprising: (a) a mediapack having inlet and outlet opposite flow faces; the media packcomprising a z-filter media construction having a network of inlet andoutlet flutes, inlet flutes being open at a region adjacent the inletface and being closed at a region adjacent the outlet face; and, outletflutes being closed adjacent the inlet face and being open adjacent theoutlet face and oriented with flutes of each fluted sheet extending in adirection between the inlet and outlet flow faces; (i) the media packhaving opposite first and second portions and opposite third and fourthportions therebetween; (ii) the third and fourth portions are longerthan the first and second portions; (b) a shell secured to the mediapack; the shell including a frame mounted against the outlet flow faceand a seal support section; (i) the frame including a media facecross-piece arrangement extending across the outlet flow face; (c) aseal member oriented against the seal support section; and (d) acartridge-handle offset from the first portion and second portion of themedia pack and projecting from the shell along the third portion of themedia pack.
 2. The air filter cartridge of claim 1 wherein the mediapack comprises a stack of strips of a fluted media sheet secured to afacing media sheet and oriented with flutes of each fluted sheetextending in a direction between the inlet face and outlet face.
 3. Theair filter cartridge of claim 1 wherein the third and fourth portionsare straight sides.
 4. The air filter cartridge of claim 1 wherein theseal member has a surface configured to from a radially outwardlydirected seal.
 5. The air filter cartridge according to claim 1 wherein:(a) the inlet flow face has a rectangular perimeter shape; and (b) theoutlet flow face has a rectangular perimeter shape.
 6. An air filtercartridge according to claim 1 wherein: (a) the seal support section hasan end tip; and (b) a portion of the seal member is positioned over theend tip.